System and method for providing carbon dioxide and circulating air for a vertical gardening system

ABSTRACT

Vertical growing uses a plurality of shelves to support plants. The system has an air filtration and ultraviolet (UV) air purification system. The purified and filtered air is mixed with nitrogen, which is directed towards plants. The system can include lights to help grow the plants placed on the shelves. The filters can remove odors from the circulating air.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/730,659, filed Oct. 11, 2017 which claims priority to U.S.Provisional Patent Application No. 62/549,919 filed Aug. 24, 2017; thisapplication further claims the benefit of priority to U.S. ProvisionalPatent Application No. 62/549,919 filed Aug. 24, 2017 and U.S.Provisional Patent Application No. 62/712,675 filed Jul. 31, 2018. Thecontents of each application are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

Vertical farming is the practice of producing food and medicine invertically stacked layers, vertically inclined surfaces and/orintegrated in other structures such as warehouses and other structuresthat can accommodate growing plants. Vertical farming use indoor farmingtechniques and controlled-environment agriculture (CEA) technology,where all environmental factors can be controlled. These facilitiesutilize artificial control of light and watering. Prior methods forcirculating air are accomplished using wall mounted oscillating fans andceiling mounted HVAC systems. However, this air circulation method isineffective in a vertical growing configuration and most verticalgardens are too compact for these environmental control methods to beefficient.

Prior methods for carbon dioxide dispersion use piping a plastic line tothe back of a wall mounted fan or a carbon dioxide generator mounted atthe ceiling in the room. Both methods do not allow for a controlleddirection of carbon dioxide. Prior methods of filtering air have beenthrough large “can filters” attached to a fan on the intake side.However, these large can filters occupy a large volume of space.

Prior methods are also generally silent on transpiration of the plantssubjected to air circulation. Transpiration is the process of watermovement through a plant and its evaporation from aerial parts, such asleaves, stems and flowers. Water is necessary for plants but only asmall amount of water taken up by the roots is used for growth andmetabolism.

The remaining 97 to 99.5% is lost by transpiration and guttation. Leafsurfaces are dotted with pores called stomata, and in most plants theyare more numerous on the undersides of the foliage. The stomata arebordered by guard cells and their stomatal accessory cells (togetherknown as stomatal complex) that open and close the pore. Transpirationoccurs through the stomatal apertures, and can be thought of as anecessary “cost” associated with the opening of the stomata to allow thediffusion of carbon dioxide gas from the air for photosynthesis.Transpiration also cools plants, changes osmotic pressure of cells, andenables mass flow of mineral nutrients and water from roots to shoots.Water vapor is removed quickly by air movement, speeding up diffusion ofmore water vapor out of the leaf. However, if there is no wind, the airaround the leaf may not move very much, raising the humidity of the airaround the leaf. Wind will move the air around, with the result that themore saturated air close to the leaf is replaced by drier air.

What is needed is system which improves the circulation of air, improvesthe distribution of carbon dioxide, uses smaller filters that occupyless space, as well as improves transpiration.

SUMMARY OF THE INVENTION

The present invention is directed towards a system and method forcirculating air and carbon dioxide and providing light to a verticalgardening system. Traditional methods of wall mounted fans do notproperly circulate air. The present invention eliminates the problem ofstagnant air pockets created in indoor vertical farming where space islimited. The present invention also disburses carbon dioxide directlyonto each row of crops growing on a different shelf of a rack assembly.This process insures that each plant receives an equal quantity ofcarbon dioxide, as opposed to common methods of releasing carbon dioxideinto a large general area with non-uniform distribution. The inventionalso provides a compact air filtration system, eliminating the need forlarge can filters commonly used.

The new invention differs from traditional methods by having the filterson the supply side of an air circulation system. This allows for the aircoming out of the fan to be disrupted, eliminating the spiral motion andpressurizes the low profile duct evenly on either side. The inventivesystem creates air movement inside each rack of plants where wall fanscan't reach and space does not allow for. The new invention allowscarbon dioxide to be plumbed into the plenum and dispersed directly tothe plants. The new invention utilizes fan or fans with a filter toclean the air as well as circulating the air. This allows for less spaceto be used, lower energy costs, and the benefit of being able to changedisposable filters more often at a much lower cost than “can filters”.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates is a side view of an embodiment of the carbon dioxidedistribution system.

FIG. 2A illustrates a top view of an embodiment of the carbon dioxidedistribution system.

FIG. 2B illustrates a perspective exploded assembly view of adistribution system.

FIGS. 2C and 2D illustrate perspective views of a distribution systemintegrated within a rack system.

FIG. 2E illustrates an perspective end view of a distribution systemwhen secured upon a rack system.

FIG. 2F illustrates a perspective view of multiple distribution systemssecured to multiple racks.

FIG. 2G illustrates a perspective view of a fan drawing air into thefilter housing of a distribution system.

FIG. 3 illustrates a front section view of an embodiment of the airintake portion of the carbon dioxide distribution system.

FIG. 4 illustrates a front section view of another embodiment of the airintake portion of the carbon dioxide distribution system.

FIG. 5 illustrates a top section view of an embodiment of the air intakeportion of the carbon dioxide distribution system.

FIG. 6 illustrates a side section view of an embodiment of the airintake portion of the carbon dioxide distribution system.

FIG. 7A illustrates a bottom view of an embodiment of the carbon dioxidedistribution system.

FIG. 7B illustrates a bottom view of another embodiment in which theopenings may be configured into rectangular or square openings.

FIGS. 7C and 7D illustrate bottom views of other embodiments in whichthe openings may be configured into varied distribution patterns.

FIG. 7E illustrates a bottom view of another embodiment in which theopenings may be varied in size along the length of the ducts.

FIG. 7F illustrates a side view of another embodiment in which the ductsmay be tapered in height along its length.

FIG. 7G illustrates a bottom view of another embodiment in which theducts may be varied in width along its length.

FIG. 8 illustrates a front view of an embodiment of the light ballast,light bar and carbon dioxide distribution ducts.

FIG. 9 illustrates a side view of a rack assembly having a carbondioxide distribution system, a grow lights system and a carbon dioxidesensor system.

FIG. 10 illustrates a view of a carbon dioxide distribution system on arack system that includes a plurality of shelves each holding aplurality of plants.

FIG. 11 illustrates a side view of multiple distribution systemsinstalled on a rack system.

FIG. 12A illustrates one embodiment of a flow diverter attached to orpositioned into proximity of the openings.

FIG. 12B illustrates a partial cross-sectional side view of a flowdiverter attached to an opening.

FIGS. 13A and 13B show side and rear views of an embodiment of the flowdiverter.

FIGS. 14A and 14B show side views of alternative embodiments of the flowdiverter having angled platforms.

FIGS. 15A to 15C show cross-sectional side views of another embodimentin which the openings may be configured so that a portion of the ductwall may be pushed directly into the channel interior.

FIG. 16 shows a perspective view of a distribution system integrateddirectly with the rack.

FIG. 17 shows a perspective view of another embodiment of a mobile rackconfigured to be re-positioned.

FIG. 18 shows an end view of a rack assembly showing multiple mobileracks which movable relative to one another.

DETAILED DESCRIPTION OF THE INVENTION

The inventive system can be used with a vertical plant growing system todisperse carbon dioxide gas to a plurality of stacked shelves that arearranged vertically in a rack placed in a room or a building. A carbondioxide distribution system can be mounted over each shelf of the rackso several carbon dioxide distribution systems can be used with eachrack. The carbon dioxide distribution system can perform variousfunctions including: circulate air around each of the plants, providesan even distribution of carbon dioxide to each of the plants and filtersthe recirculating air. A lighting system can also be attached to thebottom of the carbon dioxide distribution system that can providecontinuous grow light exposure to the plants.

With reference to FIG. 1, a side view of an embodiment of the carbondioxide distribution system 100 is illustrated and with reference toFIG. 2, a top view of an embodiment of the carbon dioxide distributionsystem 100 is illustrated. Air can be directed into an intake collar 103mounted on an inlet portion of a filter housing 101. In an embodiment, afan 105 can be used to push the air into the intake collar 103. The aircan enter the filter housing 101 and flow through one or more filters111. The filtered air can then flow into a plenum. A carbon dioxide gasinlet 113 can be coupled to the plenum and the carbon dioxide can bemixed with the filtered air. The carbon dioxide and air mixture can thenflow into one or more elongated ducts 117. Each duct 117 has a pluralityof holes or openings 102 on a lower surface and the end of the duct 117can be sealed with an end cap. The holes or openings 102 are describedin greater detail below. The elongated ducts 117 are positioned above aplurality of plants on each shelf of the rack assembly. The carbondioxide and air flow through the holes or openings 102 and onto theplants, which absorb the carbon dioxide.

With reference to FIG. 2A, in an embodiment, the fan 105 can be a 10″ ora 6″ to 14″ inline fan 105 that can be mounted in the intake collar 103at the top of the filter housing 101, as shown in the top view of thedistribution system 100. The inventive system can be used with varioustypes of vertical rack systems with plants positioned on each shelf ofthe rack system. The fan 105 can be mounted outside of the pallet rackvolume on an end of the pallet rack. In an embodiment, the fan 105 flowrate can output 1,000 cubic feet per minute (CFM). In other embodiments,any other airflow mechanism can be used with the carbon dioxidedistribution system to drive air through the system. As shown, two ducts117 may be fluidly coupled to the filter housing 101 such that theyextend in parallel relative to one another. However, a single duct mayalso be used or more than two ducts may be aligned relative to oneanother. Moreover, while the ducts 117 are shown in the top view ashaving a rectangular shape, other configurations may potentially beutilized.

Many conventional distribution systems utilize multiple fans due touneven air distribution over a plant canopy. In a typical example, two75 W fans may be placed every eight linear rack feet along a row ofcrops so that a 32 foot rack would utilize eight fans total resulting ina total of 600 W of power usage. The distribution system describedherein may utilize a single fan, e.g., 242 W, for the same 32 foot rack.The same configuration may be applied to longer rack lengths. Forinstance, a conventional fan configuration for a 40 foot rack wouldrequire ten fans, a 48 foot rack would require twelve fans, and a 64foot rack would require sixteen fans. However, each of the increasedrack lengths could utilize a single fan with the distribution systems asdescribed herein resulting in reduced power usage and lower costs.

FIG. 2B shows a perspective exploded assembly view in an example of howone embodiment of the distribution system may be assembled. Each of theducts 117 may be formed from components 117A, 117B and 117C, 117D whichmay be fluidly coupled to one another via connectors 107, 109. The ducts117 may then be fluidly coupled to the filter housing 101 via coupling106, 108, as shown. With the distribution system assembled, they may beslid or urged into place within, e.g., a pallet rack system 200 havingone or more shelves (described in further detail herein), as shown inthe perspective views of FIGS. 2C and 2D. The illustrations show how oneassembled distribution system 100 may be attached below a first shelf110 so that the air and/or carbon dioxide may be distributed from theduct 117 and onto any plants which may be placed upon a second shelf 112located below the first shelf 110 and duct 117. With the distributionsystem secured upon the rack 200, the filter housing 101 may bepositioned to extend from the rack 200 to allow for positioning of thefan and access to the filter housing 101.

The distribution system may be attached via one or more structuralelements 114 such as braces, retaining brackets, etc. which allow forthe distribution system to be slidingly secured or removed from the racksystem 200, as shown. If desired, a second distribution system may besecured to the top of the rack system 200 so that air and/or carbondioxide may be distributed upon any plants placed upon the first shelf110 below the second distribution system.

The shelves in any of the embodiments described herein may vary in thenumber of shelves utilized per rack and may also vary in size. Forexample, one variation of the one or more shelves may each range inlength from, e.g., 8 ft. to 64 ft., and in width from, e.g., 2 ft. to 4ft. Various configurations of the shelf may range, e.g., 4 ft.×8 ft.; 3ft.×8 ft.; 2 ft.×8 ft.; 4 ft.×4 ft.; 4 ft.×3 ft.; 4 ft.×2 ft., etc.

Additionally, the vertical distance between each shelf of a rack may beadjusted depending upon various factors, e.g., desired number of shelvesor spacing between each shelf, growth phase of plant, etc. For instance,the distance between each shelf may be varied from, e.g., 12 in. to 48in. when the plants are in their vegetative cycle, 36 in. to 96 in. whenthe plants are in their flower cycle, etc.

The racks as well as shelves may be constructed from various materials,e.g., powder coated square steel, aluminum, etc. Additionally and/oralternatively, one or more of the shelves may be configured to define aslope towards one specified corner or edge relative to horizontal forfacilitating drainage of water or other liquids from the plantspositioned upon the shelves.

FIG. 2E shows a perspective end view of another embodiment in which thedistribution system has been secured below a shelf 110 of the rack 200.As illustrated with the filter housing 101 and fan 105 extending fromthe rack 200, the two parallel ducts 117 may be seen extending from thefilter housing 101 and along the length of the rack with the pluralityof openings 102 aligned along the bottom surface of the ducts 117 fordistributing air and/or carbon dioxide upon any plants positionedbeneath.

FIG. 2F shows a perspective view of another embodiment in which multipledistribution systems may be utilized with multiple racks positionedadjacent to one another. In this example, a first distribution system119 may be seen secured to a first rack 202 with a second distributionsystem 120 secured to a second rack 203 adjacent to the first rack 202.Any number of distribution systems may be utilized with any number ofracks depending upon the desired configuration.

FIG. 2G illustrates a perspective view of how the fan 105 may be used todraw air 204 into the filter housing 101. The air may be provided viaambient air drawn into the fan 105 or via tubing or ducting fluidlycoupled to the fan 105 where the air (or other gas) may be drawn fromanother location or reservoir. With the air 204 drawn into the fan 105,through the filter 111, and into the filter housing 101, the air 204 maybe optionally mixed with carbon dioxide (or any other gas) and themixture 205 may be conveyed through the ducts 117 for distribution.

With reference to FIG. 3, a cross section front view of an embodiment ofthe filter housing 101 is illustrated. In this embodiment, there are twofilters 111 that are held in angled positions by channel brackets 115.With reference to FIG. 4, another cross section front view of anembodiment of the filter housing 101 is illustrated. In this embodiment,there are two filters 111 that are held in flat positions by the channelbrackets 115. Air flows through the center portions of the filters 111so the brackets 115 only contact the edges of the filters 111. In otherembodiments, the filters 111 can be held by any other holdingmechanisms. With reference to FIG. 5 a top sectional view of anembodiment of the filter housing 101 illustrated. A fan can be mountedwithin the intake collar 103 which can be attached to the air inlet ontop of the filter housing 111. The fan can blow air into the filterhousing 101 and through the filters 111.

With reference to FIGS. 3-5, the filters 111 can be mounted across thewidth of the filter housing 101 so that air from the inlet must flowthrough one of the filters 111. In this example, a first filter 111 ison one side of the filter housing 101 and a second filter 111 is on anopposite side of the filter housing 101. In an embodiment with referenceto FIG. 3, the filters 111 can be angled rather than horizontallyoriented within the filter housing. The edge of the filters 111 at thecenter of the filter housing 101 can be lower than the edges of thefilters 111 at the outer sides of the filter housing 101. The filters111 can be mounted on support structures which can be channel brackets115 that extend across the length of the filter housing 101. In anembodiment, the support structures channel brackets 115 can have groovesthat securely hold the inner and outer edges of the filters 111 in placewithin the filter housing 101. The filter housing 101 can have a hingeddoor that can be open to access the filters 111. The filters 111 can beremoved and replaced when the hinged door is opened and the filters 111can be locked in place within the filter housing 101 when the hingeddoor is closed.

The filters 111 can trap particulates from the plants, which can bebeneficial when the plants being grown are very aromatic. Terpenes are agroup of organic molecules derived from isoprene that are present infruits, vegetables and vegetation. Terpenes are derived biosyntheticallyfrom units of isoprene and the basic molecular formula is (C₅H₈). Theseterpenes cause the specific odors for example: limonene in citrus fruit,pinene in pine tree. Marijuana is also a plant that produces terpenes.Because the smell of terpenes can be a nuisance to the surroundingareas, it can be highly beneficial to remove the marijuana terpenes thathave been released into the air by the cannabis plants. In anembodiment, the filters used with the system can be terpene filters thatremove terpenes from the circulating air in the plant grow building. Byremoving terpenes from the air, the odor generated by the building wherethe plants are grown can be greatly reduced so that the building is nota nuisance to the surrounding community. When the terpenes saturate thefilters 111, the door to the filter housing 101 can be opened and thefilters 111 can be removed and replaced with clean filters 111. The usedfilters 111 can be placed in sealed bags so that the odors arecontained.

When the air enters the plenum through the fan 105, the air must passesthrough the air filters 111. In an embodiment, the filters 111 can havethe dimensions, 12″×20″×1″. This process disrupts the spiraling air flowcreated by the fan 105 and allows both sides of the supply runs topressurize and distribute even amounts of air through the 1.125″ ductexit holes. This was unachievable with a direct fan to supply runconfiguration. The process also eliminates the need for a separate fanand carbon filter to be installed in the room.

In an embodiment, a pressure sensor(s) 121 can be mounted in the filterhousing 101 to measure static pressure and a differential pressureacross the filters 111. This information can be used to determine theflow resistance through the filter 111 and the flow rate through thesystem. If a first pressure sensor 121 is mounted in the filter housing101 upstream of the filter 111 and a second pressure sensor 121 ismounted in the filter housing 101 downstream of the filter 111, thedifferential pressure across the filters 111 can be measured. A cleanfilter 111 will allow air to more easily flow through the filter 111 andwill have a lower differential pressure than a dirty filter 111. In anembodiment the system can have a processor 123 that is coupled to thepressure sensors 121 that monitor the differential pressure and theprocessor 123 can issue notifications when the differential pressureexceeds a predetermined value. The operator will then know that thefilter(s) 111 need to replaced.

In another embodiment, the system sensor 121 and processor 123 canmonitor the static pressure of the pressure up stream of the filter 111.This monitoring system can depend upon the air input providing aconstant power or flow rate into the system. As the filter(s) 111becomes dirty, the static pressure upstream of the filter(s) 111 willincrease and when the upstream static pressure exceeds a predeterminedvalue, the monitoring system can inform the operator who will then knowthat the filter(s) 111 need to replaced. Conversely, the system canmonitor the static pressure of the pressure down stream of the filter(s)111. As the filter(s) 111 becomes dirty, the static pressure downstreamof the filter 111 will decrease and when the down stream static pressurefalls below a predetermined value, the monitoring system can inform theoperator who will then know that the filter(s) 111 need to replaced.

With reference to FIG. 6, a side sectional view of the filter housing101 is illustrated showing the carbon dioxide inlet 127 couplingattached to the bottom of the filter housing 101. The carbon dioxideinlet 127 in the illustrated example, can have a threaded insert whichis bolted to the inner surface filter housing 101 which forms a sealwith the filter housing 101 and prevents carbon dioxide gas leakage. Aninlet coupling 127 extends from the filter housing 101. In anembodiment, the inlet coupling 127 can be a nipple which can be coupledto tubing 129 that can be used to deliver carbon dioxide to the filterhousing 101. The carbon dioxide inlet coupling 127 can be coupled withtubing 129 to a carbon dioxide gas source 131 such as a carbon dioxidetank or other carbon dioxide supply. In an embodiment, a control valve135 can be coupled between the carbon dioxide gas source 131 and thefilter housing 101. The control valve 135 can be coupled to a carbondioxide controller, which can monitor the carbon dioxide levels in thebuilding or at the plant levels. The carbon dioxide controller canmaintain a predetermined carbon dioxide level by decreasing the carbondioxide flow when the detected carbon dioxide level is too high andincrease the carbon dioxide flow when the detected carbon dioxide levelis too low.

With reference to FIG. 7A, a bottom view of an embodiment ofdistribution ducts 117 of the carbon dioxide distribution system 100 isillustrated. Air and carbon dioxide flow through the ducts 117 from theproximal end attached to the filter housing 101 to the distal end of theducts 117. The air and carbon dioxide will flow out of the holes oropenings 135 on the bottom of the ducts 117. In an embodiment, the holes135 can be 1.125 inch diameter holes. However, in other embodiments, theholes or openings 135 can be any suitable size such as 0.5 inch to 2.0inch diameters. In addition, while the holes or openings 135 are shownas having an alternating distribution pattern between each adjacent row,the holes or openings 135 may alternatively have a uniform distributionor other distribution pattern, as described further below.

The distribution ducts 117 can be a metal duct system made from aluminumor galvanized sheet metal. The distribution ducts 117 can be designed tobe as thin as possible while still providing desired flow rate of carbondioxide and velocity of air movement over a vertical gardeningapplication. This can be accomplished by using a thin cross sectiondistribution duct 117 so that the ducts consume very little verticalspace. For example, the ducts 117 can have a cross section that is about3 inches high and about 16 inches wide. This height to width (H/W) ratiocan be known as the aspect ratio. In this example, the aspect ratio is3/16=0.1875. In an embodiment, the aspect ratio of the ducts 117 is lessthan 0.25. The flow rate of the air and carbon dioxide can be quantifiedwith a flow rate metric such as cubic feet per minute (CFM). The carbondioxide and airflow eliminates warm pockets of air by providingconcentrated air movement, carbon dioxide dispersion, and filtration.

FIG. 7B shows a bottom view of another embodiment of the distributionsystem which defines a plurality of rectangular or square openings 136aligned in a uniform distribution pattern along the lengths and widthsof the ducts 117. Each of the openings 136 in this variation may rangein length (along the direction of the longitudinal axis of the duct 117)and in width (transverse to the longitudinal axis of the duct 117).Additionally, the number of openings 136 may also vary so long as thetotal area of the openings range as a percentage of the total surfacearea of the ducts 117 upon which the openings 136 are defined.

As described herein, the fan 105 can be mounted outside of the palletrack volume on an end of the pallet rack. In one embodiment, the fan 105flow rate can output 1,000 CFM while in other embodiments, the systemmay output between, e.g., 5.5 to 8 CFM at a rate of, e.g., 600 to 800ft/min. The output CFM may be obtained at a distance of, e.g., 4 to 6inches, above the plant canopy to provide adequate air movement withoutoverstressing the underlying plants. A controller may be used to adjustthe volume and velocity depending on, e.g., the distance between thedistribution system and the plants. The distribution system and flowrates may be configured so that the flow exiting the openings 136 alongthe ducts 117 is balanced along the length of the ducts 117. Forinstance, the flow rate from a proximal location as compared to the flowrate from a distal location along the ducts 117 may vary within, e.g., 1to 2 CFM, and, e.g., 100-200 ft/min, along racks up to, e.g., 56 feet inlength.

With the flow parameters configured with the distribution system,transpiration in plants treated with the distribution system mayimprove. For instance, a 30 to 40% increase in transpiration may result.

Instead of a uniform distribution pattern, the openings may be definedin alternative patterns. For instance, FIG. 7C shows a bottom view ofanother embodiment in which the length of the ducts 117 may be separatedinto increasing numbers of openings for each subsequent region away fromthe filter housing 101. A first region 138 may define a first number ofopenings, a second region 139 distal to the first region 138 may definea second number of openings which is greater than the first number, anda third region 140 distal to the second region 139 may define a thirdnumber of openings which is greater than the second number of openings.The number of regions and the number of openings defined within eachregion may be varied depending upon the distribution of the air as wellas other parameters such as pressure, flow rates, etc. Additionallyand/or alternatively, while the patterns are shown to be identicalbetween each of the adjacent ducts 117, the pattern on the first ductmay be different from the pattern on the second duct, if so desired.

FIG. 7D shows another embodiment in which the duct may define a firstregion 142 having a first uniform distribution of openings, and a secondregion 144 distal to the first region 142 having a second uniformdistribution of openings. In this embodiment, the second region 144defines the second uniform distribution which is relatively more dense(e.g., having a larger total area of openings) than the first uniformdistribution. As discussed above, the number of regions and the numberof openings defined within each region may be varied depending upon thedistribution of the air as well as other parameters such as pressure,flow rates, etc. Additionally and/or alternatively, while the patternsare shown to be identical between each of the adjacent ducts 117, thepattern on the first duct may be different from the pattern on thesecond duct, if so desired.

FIG. 7E shows yet another embodiment in which the distribution systemdefines several regions with uniform distribution of openings but withthe openings varying in size so that the total area of the openingsincreases distally along the length of the ducts. A first region 146 mayhave a distribution of first openings having a first size. A secondregion 148 distal to the first region 146 may have a distribution ofsecond openings having a second size which is relatively larger than thefirst size. A third region 150 distal to the second region 148 may havea distribution of third openings having a third size which is relativelylarger than the second size. Likewise, a fourth region 151 distal to thethird region 150 may have a distribution of fourth openings having afourth size which is relatively larger than the third size, and so on.As discussed above, the number of regions and the number of openingsdefined within each region may be varied depending upon the distributionof the air as well as other parameters such as pressure, flow rates,etc. Additionally and/or alternatively, while the patterns are shown tobe identical between each of the adjacent ducts 117, the pattern on thefirst duct may be different from the pattern on the second duct, if sodesired.

Additionally and/or alternatively, the ducts 117 may also be varied inheight to adjust for the parameters such as pressure, flow rates, etc.relative to the length of the duct. FIG. 7F shows yet another embodimentin the side view of a distribution system in which the duct 117 may betapered or otherwise reduced in height the further distal relative tothe filter housing 101. For example, the duct may have a first height H1where the duct joins the filter housing 101 but the lower and/or uppersurface 152 may be tapered such that the ending height H2 of the duct atthe distal end may be reduced. Another alternative embodiment is shownin the bottom view of FIG. 7G which illustrates ducts 117 which may bereduced in cross-sectional width the further distal relative to thefilter housing 101. The example shown illustrates a first region 153having a first width, a second region 154 distal to the first region 153and having a second width which is smaller than the first width, and athird region 155 distal to the second region 154 and having a thirdwidth which is smaller than the second width. As discussed above, thenumber of regions and the number of openings defined within each regionmay be varied depending upon the distribution of the air as well asother parameters such as pressure, flow rates, etc. Additionally and/oralternatively, while the patterns are shown to be identical between eachof the adjacent ducts 117, the pattern on the first duct may bedifferent from the pattern on the second duct, if so desired.

Furthermore, any of the features in one embodiment may be combined withanother feature from another embodiment depending upon the desired flowcharacteristics, e.g., pressure, flow rate, etc. For instance, thetapered height of the ducts 117 may be combined with openings 136 whichare uniform in distribution or varied in distribution patterns and/orsize of the openings. Other combinations are intended to be within thescope of the disclosure.

In addition to providing carbon dioxide to the plants on the racksystem, embodiments of the present invention incorporate grow lightsthat emit light that is directed towards the plants. With reference toFIG. 8, a front view of an embodiment of the carbon dioxide distributionducts 117 and grow light bar 145 used with the carbon dioxidedistribution system 100 is illustrated. The grow light components caninclude a light ballast 143, a heat sink 141 and light bars 145 whichhold a plurality of light emitting diodes (LEDs). Electrical power suchas 110V AC or 220V AC is supplied to the light ballasts 143, whichprovide the required electrical power to the LED grow lights in thelight bars 145. The ballasts 143 can limit the amount of current fromsupply line voltage, while maintaining the necessary electricalconditions for proper lamp start and operation. In this embodiment, theballast 145 can be mounted under the lower surfaces of the air ducts117. The ducts 117 can in physical contact with the light bars 145 andthe ballasts 143. The ducts 117 can function as heat sinks for heatgenerated by the light bars 145 and the ballast 143. The ducts 117 canbe dissipate the heat from the ballasts 143 and the light bars 145 toprevent over heating. Similarly, the heat sink 141 can help to dissipatethe heat generated by the ballasts 143.

With reference to FIG. 9, a front view of another embodiment of thecarbon dioxide distribution ducts 117 and grow lights 145 used with thecarbon dioxide distribution system 100 is illustrated. In thisembodiment, the light bar grow light bar 145 is supported by cables 149which can be adjustable in length to adjust the height position of thelight bar 145. The light bar 145 can be electrically coupled to theballast 143 with an electrical cable 147.

In an embodiment with reference to FIG. 10, the filter housing 250 caninclude a pre-filter 251, disinfectant lights 255 and a secondary filter253. The pre-filter 251 and the secondary filter 253 can be planarstructures that are substantially parallel to each other. The lights 255can be elongated tubular structures that extend across the width of thefilter housing 250. In an embodiment, the lights 255 can besubstantially parallel to each other and the pre-filter 251 and thesecondary filter 253. The lights 255 can be vertically aligned with eachother.

The Air exiting the filter housing 250 is directed towards the gasdistribution ducts as described above. In the example, air is forcedthrough a fan housing 103 and a pre-filter 251 into a light exposurespace between the pre-filter 251 and a secondary filter 253. When theair is in between the pre-filter 251 and the secondary filter 253 theair is exposed to short-wavelength ultraviolet (UV-C) light, whichresults in ultraviolet germicidal irradiation (UVGI) of particles in theair. The UVGI is a disinfection method that uses UV-C light to kill orinactivate microorganisms by destroying nucleic acids. UVGI devices canproduce strong enough UV-C light in circulating air systems to make theminhospitable environments to microorganisms such as bacteria, viruses,molds and other pathogens. UVGI can effectively provide air purificationto the inlet air.

UV light is electromagnetic radiation with wavelengths shorter thanvisible light. UV can be separated into various ranges, withshort-wavelength UV (UVC) considered “germicidal UV”. At certainwavelengths, UV is mutagenic to bacteria, viruses and othermicroorganisms. Particularly at wavelengths around 250 nm-270 nm, UVbreaks molecular bonds within microorganism DNA, producing thyminedimers that can kill or disable the organisms. In an embodiment, thesystem can have three 33 inch long, 120V, 25 Watt UV-C lamps that eachproduce a light intensity of 302 μW/cm². The lights are mounted in theplenum that eliminates surface bacteria, mold, and viruses from thesystem.

In different embodiments, various different types of lights can be usedfor the UVGI disinfectant air processing. For example, mercury-basedlamps emit UV light at the 253.7 nm line, Ultraviolet Light EmittingDiodes (UV-C LED) lamps emit UV light at selectable wavelengths between255 and 280 nm, and Pulsed-xenon lamps emit UV light across the entireUV spectrum with a peak emission near 230 nm.

The effectiveness of germicidal UV can depends on the length of time amicroorganism is exposed to UV, the intensity and wavelength of the UVradiation, the presence of particles that can protect the microorganismsfrom UV, and a microorganism's ability to withstand UV during itsexposure. In many systems, redundancy in exposing microorganisms to UVis achieved by circulating the air repeatedly. This ensures multiplepasses so that the UV is effective against the highest number ofmicroorganisms and will irradiate resistant microorganisms more thanonce to break them down.

The effectiveness of this form of disinfection depends on line-of-sightexposure of the microorganisms to the UV light. The lights 255 areplaced in a direct line of sight for optimum for disinfection of theair. In an embodiment, the effectiveness and UV intensity can beachieved by using reflection. The interior surface of the filter housing250 can have reflective surfaces so that the UV light can reflect backinto the vent housing and expose more air to UV light. Aluminum can havea polished high reflectivity surface, which can improve the UVGIprocessing.

In air disinfection applications the UV effectiveness is estimated bycalculating the UV dose which will be delivered to the microbialpopulation. The UV dose is calculated through the equation: UV doseμWs/cm²=UV intensity μW/cm²×Exposure time (seconds). The UV intensity isspecified for each lamp at a distance of 1 meter. In the air ductapplication, the exposure time is short so the UV intensity must be highand output by multiple UV lamps. The UV lights are located in a straightduct section with the lamps perpendicular to the air flow to maximizethe exposure time. The UV dose is the amount of germicidal UV energyabsorbed by a microbial population over a period of time. UVGI can beused to disinfect air with prolonged exposure. Disinfection is afunction of UV intensity and time.

The pre-filters can keep dust particles out of the ducts of the systemand prevent dust particles from being placed on the plants. Thesecondary filters can slow the air flow through the filter housing,giving the UV light more time to eliminate pathogens in the air. Thepre-filter and the secondary filter are positioned to prevent lightescaping the filter housing, which would be harmful to plants andpeople. The pre-filter and secondary filter can be carbon activated toreduce odors. The pre-filter and secondary filter can be black in colorand absorb the light output by the UV light. The pre-filter andsecondary filter can be opaque and the light output by the UV light frombeing transmitted through the pre-filter and secondary filter. Thepre-filter and secondary filter does not reflect light which can preventthe UV light from escaping the filter housing.

With reference to FIG. 11, the carbon dioxide distribution system can beused with a rack system 200 that includes a plurality of shelves 201that provide a plurality of vertically aligned areas for growing plants211. Air can be directed through fans 103 into filter housings 250 whichcan include a pre-filter, UV lights and a secondary filter. Thepre-filter and secondary filter remove particles from the air and the UVlight can disinfect the air. The purified air is mixed with the carbondioxide and directed towards the ducts The ducts 117 of the carbondioxide distribution systems can be mounted above each of the shelves201 so that carbon dioxide can be delivered directly to the plants 211.The light bars 145 can also be mounted directly over the plants 211 sothat exposure to the grow lights is maximized. An example of a palletrack 200 is the PiPP mobile storage systems rack shelving system thathas two basic components, beams and frames which are assembled to buildracks with stacked shelves 201.http://www.pippmobile.com/Products/Shelving-Systems/Pallet-Rack.aspx

The carbon dioxide system can be configured to maintain a specific levelof carbon dioxide in a grow room. For example, in an embodiment, thesystem may be configured to maintain the carbon dioxide level atapproximately 1,500 ppm. The system can include carbon dioxide sensors221 coupled to a controller 225 that controls flow control values 135coupled to the carbon dioxide source 131. By altering the positions ofthe control valves 135, the flow rates of carbon dioxide to the carbondioxide distribution systems can be adjusted. The controller 225 cancontrol the flow rate to maintain an optimum carbon dioxide level andprevent the carbon dioxide level from becoming dangerous. When thecarbon dioxide level is too high (for example, above, 2,000 ppm), thesensors 221 can detect this excess carbon dioxide and reduce the flowrate of carbon dioxide into the distribution system. Conversely, if thecarbon dioxide level is detected as being lower than 1,000 ppm, thecontroller 225 can open the control vales 135 to increase the carbondioxide levels through the carbon dioxide distribution system. If thecarbon dioxide source 131 is tanks a pressure sensor 137 can be mountedto the tank. If the pressure in the tank drops below a predeterminedlevel, the system can inform the operator that the carbon dioxide tankshould be replaced.

If the carbon dioxide level exceeds a level of 3,000, the system canissue a warning indicating that there can be a carbon dioxide controlproblem and the control system should be inspected. If the carbondioxide level exceeds a level of 5,000, the system can issue a warningindicating that the carbon dioxide level exceeds the workplace exposurelimit and warning people not to enter the room. With reference to Table1 below a listing of carbon dioxide levels and the human reaction toexposure to the carbon dioxide gas.

TABLE 1 Listing of carbon dioxide levels and human reaction to exposure.Carbon Dioxide level 250-350 ppm Normal carbon dioxide level in outdoorambient air   250-1,000 ppm Normal carbon dioxide level in indoor air1,000-2,000 ppm Poor quality air and complaints of drowsiness2,000-5,000 ppm Headaches and sleepiness, increased heart rate andnausea. 5,000+ ppm Exceeds workplace exposure limit

The ducts 117 can run along the length of the rack shelves 201 and thelight bars 145 can extend across the width of the shelves 201. In thisembodiment, the light bars 145 can be suspended with wires or othersupports below the ducts. In other embodiments, the light bars 145 canbe mounted directly to the bottom of the ducts 117. In an embodiment,the height of the light bars 145 over the plants 211 can be adjustable.The light bars 145 can be positioned so that the LED lights may be 12-18inches above the plants 221. As the plants 211 grow, the verticalpositions of the light bars 145 may be adjusted to provide the optimumgrow light exposure to the plants 211.

While the openings distributed along the bottom of the ducts 117 may bevaried in size, pattern, etc., additional features may be incorporatedto further enhance the flow of air through the openings. One example isshown in the perspective view of FIG. 12A which illustrates flowdiverters 260 which may be attached to or positioned into proximity ofthe openings, e.g., secured to the distal edge of the opening relativeto the direction of airflow through the duct 117. The flow diverters 260may be attached to one or more of the openings, e.g., to a select numberof openings to enhance the flow along a particular region of the ducts,or to all the openings.

One embodiment of a flow diverter 260 is shown in the partialcross-sectional side view of FIG. 12B which illustrates a flow diverter260 attached to the opening 136. The flow diverter 260 may have adiverter platform 261 which defines a flow surface 262. The diverterplatform 261 may incorporate a first gusset 263 and an apposed secondgusset 264 such that the first gusset 263 and second gusset 264 extendtowards one another to define a securement channel 265 which enables theflow diverter 260 to be removably slid upon a portion of the duct 117and secured for use. As shown, a portion of the platform 261 may extendbeyond the gussets 263, 264. As the flow diverter 260 may be configuredfor placement through the openings of the ducts 117, the diverter 260may have a range of widths and a range of lengths. Moreover, while thediverter 260 is shown with a platform 261 which is flat, the platform261 may be configured into other shapes, e.g., curved, convex, concave,etc.

In one example of use, the flow diverter 260 may be secured to the duct117 so that the platform 261 extends at least partially into the channelinterior CI so that a portion of the airflow AF encounters the flowsurface 262 and is forced through the opening 136 as diverted flow DF.FIGS. 13A and 13B show side and rear views of an embodiment of the flowdiverter 260. As illustrated, a single first gusset 263 may bepositioned in apposition to two second gussets 264A, 264B so that thesecurement channel 265 for attachment to the duct 117 presents analternating securement mechanism. Alternative securement mechanisms mayalso be incorporated with the flow diverter 260.

While the platform 261 may extend transversely, e.g., at 90°, into thechannel interior CI relative to the duct 117 when the diverter 260 issecured for use, the platform 261 may be configured so that the platform261 presents an angled flow surface 262 relative to the channel interiorCI and duct surface. One embodiment is shown in the side view of FIG.14A which illustrates a flow diverter 270 having an angled platform 261.The platform 261 is configured such that when secured for use, the flowsurface 262 presents an acute angle Θ1, as illustrated by the angle Θ1defined between the duct surface 271 and platform angle 272. The acuteangle Θ1 may range from, e.g., 0° to 89°.

Another embodiment is shown in FIG. 14B which illustrates a flowdiverter 273 having an angled platform 261 configured such that whensecured for use, the flow surface 262 presents an obtuse angle Θ2 whichmay range from, e.g., 91° to 180°. The angle at which the platform 261is configured may vary depending upon the desired amount of flow to bediverted through the opening.

It is intended that any of the flow diverters 260 may be used with anyof the different distribution systems described herein and with any ofthe variations of the openings as well.

In another embodiment, the ducts may be configured to provide the flowdiversion rather than attaching a separate mechanism. FIGS. 15A to 15Cshow cross-sectional side views of another variation in which theopenings may be configured so that a portion of the duct wall may bepushed directly into the channel interior CI (e.g., push-in tabconnected via a living hinge) to function as a flow diverter 280. Asshown, the flow diverter 280 may be pushed into the channel interior CIso that the angle α defined by the diverter 280 relative to the ductsurface forms an obtuse angle, as shown in FIG. 15A, a transverse rightangle, as shown in FIG. 15B, or an acute angle, as shown in FIG. 15C.

In yet another variation, rather than utilizing racks which are separatefrom the ducts, the ducts 117 may be integrated directly with the racksto form a combined rack and air distribution system, as shown in theperspective view of FIG. 16. The rack system 300 may directlyincorporate one or more of the ducts 117 directly below the shelves 301,302 by being secured directly under the respective shelf, e.g., bolted,screwed, riveted, braced, etc. while the filter housing 101 and fan 105may be mounted on one or both ends of each row or racking. With thisembodiment and with any of the other embodiments described herein, theracks may incorporate a single shelf, two shelves, or multiple shelves(e.g., up to six shelves or more than six shelves) depending upon thedesired number of shelves.

The braces supporting the rack 300 may also be configured to allow forthe placement of the ducts 117 with minimal interference to the shelfplatforms so that access to the shelves 301, 302 remains unhindered. Inone embodiment, the braces may be configured into a diagonal cross-brace304 between the rack supports while a second cross-brace 303 may extendhorizontally between the rack supports relative to a surface of theshelf and positioned at a distance from the shelf surface so as toprovide unhindered access to the shelf.

With this embodiment or any of the other rack and distribution systemsdescribed herein, any of the racks may be placed upon a floor orplatform or secured in place upon the floor or platform. Alternatively,any of the racks may be configured to be mobile to allow for positioningor re-positioning of the racks relative to one another in order tofacilitate access to multiple racks. An example of one embodiment isshown in the perspective view of FIG. 17 which illustrates a singlemobile rack 310 having a controller unit 311 with an actuation mechanism312 which may be used to move the rack 310. The rack 310 may be mountedupon one or more carriages 313 which can slide or roll upon one or moretracks 314 secured to the platform or floor. When the actuationmechanism 312 is actuated, e.g., mechanically, electronically, etc., therack 310 may slide or roll upon the tracks 314 in a first or seconddirection 315.

FIG. 18 shows an end view of an example of a rack assembly 320 showinghow multiple racks 310-1, 310-2, . . . , 310-n may be aligned directlyadjacent to one another in order to preserve space for efficientvertical farming. The rows of racks may each have plants positioned upontheir respective shelves and the distribution system positioned uponeach rack may include any of the different embodiments described herein.

Each of the racks (or a select number of the racks) may be mounted upona respective carriage 313 configured to slide or roll upon one or moretracks 314. Each of the racks may be positioned directly next to oneanother during use and when access to a particular rack is needed, theactuation mechanism 312 of a rack may be actuated to create a space 321between the respective racks to provide sufficient access space. Theracks may be moved individually or several at a time accordinglydepending upon which rack is accessed.

The present disclosure, in various embodiments, includes components,methods, processes, systems and/or apparatus substantially as depictedand described herein, including various embodiments, subcombinations,and subsets thereof. Those of skill in the art will understand how tomake and use the present disclosure after understanding the presentdisclosure. The present disclosure, in various embodiments, includesproviding devices and processes in the absence of items not depictedand/or described herein or in various embodiments hereof, including inthe absence of such items as may have been used in previous devices orprocesses, e.g., for improving performance, achieving ease and/orreducing cost of implementation. Rather, as the flowing claims reflect,inventive aspects lie in less than all features of any single foregoingdisclosed embodiment.

1. A flow distribution assembly, comprising: a filter housing having anair inlet portion; a first elongated duct fluidly coupled to a firstoutlet portion of the filter housing and having a first plurality ofopenings defined on a lower surface of the first elongated duct; asecond elongated duct fluidly coupled to a second outlet portion of thefilter housing adjacent to the first outlet portion and having a secondplurality of openings defined on a lower surface of the second elongatedduct, and wherein the first elongated duct and second elongated ductextend adjacent to one another from the filter housing such that theflow distribution assembly is positionable upon a rack.
 2. The assemblyof claim 1 further comprising: a pre-filter; a UV light; and a secondaryfilter mounted in the filter housing between the air inlet portion andthe outlet portion of the filter housing.
 3. The assembly of claim 2further comprising a carbon dioxide input coupled to the outlet portionof the filter housing.
 4. The assembly of claim 3 further comprising afan fluidly coupled to the filter housing, wherein the fan directsambient air into the filter housing.
 5. The assembly of claim 4 whereinfiltered air is exposed to the UV light and mixed with the carbondioxide, the air and carbon dioxide flows through the plurality of holesin the elongated duct to plants growing under the elongated duct.
 6. Theassembly of claim 2 wherein the pre-filter and the secondary filter areeach planar and substantially parallel and opaque to light emitted bythe UV light.
 7. The assembly of claim 2 wherein the UV light ispositioned between the pre-filter and the secondary filter.
 8. Theassembly of claim 2 further comprising a second UV light mounted in thefilter housing.
 9. The assembly of claim 4 wherein the fan directs theambient air in a downward direction and the first elongated duct isoriented in a horizontal direction.
 10. The assembly of claim 2 whereinthe UV lights output light wavelengths between 250 nm and 270 nm. 11.The assembly of claim 1 wherein at least the first plurality of openingscomprise rectangular or square shapes.
 12. The assembly of claim 1wherein at least the first plurality of openings define an increasingsize of the first plurality of openings distal to the filter housing.13. The assembly of claim 1 wherein at least the first elongated ducttapers from a first height to a second height which is lower than thefirst height along a length of the first elongated duct.
 14. Theassembly of claim 1 wherein at least the first elongated duct defines adecreasing width of the first elongated duct along a length of the firstelongated duct.
 15. The assembly of claim 1 further comprising one ormore flow diverters configured for securement within or in proximity toat least one of the first plurality of openings.
 16. The assembly ofclaim 15 wherein the one or more flow diverters comprises: a diverterplatform; a first gusset; and a second gusset apposed to the firstgusset such that a securement channel is defined between first andsecond gussets.
 17. The assembly of claim 16 wherein the diverterplatform is angled relative to a surface of the first elongated duct.18. The assembly of claim 1 wherein at least the first plurality ofopenings comprise a flow diverter extending from an edge of at least oneopening.
 19. The assembly of claim 1 wherein the first and secondelongated ducts are integrated with the rack.
 20. The assembly of claim1 wherein the rack is configured to slide or roll.
 21. A method ofdistributing flow, comprising: positioning a first elongated duct and asecond elongated duct upon a rack, wherein each of the first and secondelongated ducts is fluidly coupled via an outlet portion to a filterhousing and extends adjacent to one another along the rack; introducingair through an air inlet portion and into the filter housing which ispositioned external to the rack and into the first and second elongatedducts; and distributing the air through a first plurality of openingsdefined on a lower surface of the first elongated duct and through asecond plurality of openings defined on a lower surface of the secondelongated duct.
 22. The method of claim 21 wherein introducing airfurther comprises: filtering the air via a secondary filter mounted inthe filter housing between the air inlet portion and the outlet portion,and/or exposing the air to a UV light.
 23. The method of claim 21further comprising introducing carbon dioxide into the air.
 24. Themethod of claim 21 wherein distributing the air comprises distributingthe air to one or more plants positioned below at least the firstelongated duct.
 25. The method of claim 21 wherein distributing the aircomprises flowing the air through at least the first plurality ofopenings having rectangular or square shapes.
 26. The method of claim 21wherein at least the first plurality of openings define an increasingdistribution of openings distal to the filter housing.
 27. The method ofclaim 21 wherein at least the first plurality of openings define anincreasing size of the first plurality of openings distal to the filterhousing.
 28. The method of claim 21 wherein at least the first elongatedduct tapers from a first height to a second height which is lower thanthe first height along a length of the first elongated duct.
 29. Themethod of claim 21 further comprising diverting airflow through at leastthe first plurality of openings via one or more flow diverters.
 30. Themethod of claim 21 further comprising adjusting a position of the rackrelative to a second rack.